Pre-Folded File Bottom Box Form, and Method of Creating Same

ABSTRACT

A pre-folded file bottom box form ( 80 ) created from a unitary blank ( 10 ) of corrugated material that is die cut and creased so as to form a series of panels and flaps arranged in three rows (A, B and C) of four panels or flaps each that define four columns (D, E, F and G). The blank ( 10 ) includes a first row (A) with four panels ( 32, 34, 36  and  38 ) that end up in the box as reinforcing sidewall and end wall panels, a middle row (B) contiguous with the first row (A) and having four panels ( 20, 24, 28  and  40 ) that end up in the box as sidewall and end wall panels, and a third row (C) coupled to the second row (B) and including first ( 16 ) and second ( 18 ) panels and two flaps ( 12, 14 ), the first ( 16 ) and second ( 18 ) panels making up the bottom of the box and the two flaps ( 12, 14 ) contiguous with the first third-row panel ( 16 ) and making up portions of the two end-walls. The four panels of the first row (A) are folded onto the four panels of the second row (B). The blank is then folded along two of the fold lines ( 42, 44 ) located between columns, and the edges ( 24, 26 ) of the end panels ( 30, 20 ) of the middle row (B) are fastened together, to create the completed form ( 80 ).

CROSS-REFERENCE TO RELATED APPLICATION

This application claims priority of Provisional Application Ser. No.61/492,912 filed on Jun. 3, 2011, the disclosure of which isincorporated herein by reference.

FIELD

This disclosure relates to a form that is constructed and arranged to befolded into a cardboard box.

BACKGROUND

File bottom record/archive file storage boxes are historically made in afashion that requires a great deal of complex, manual assembly by theconsumer. The existing state of the art “file bottom” style, in whichthe bottom is created from flaps as the box form is folded into a box,requires more time and space than is desirable. The file bottom styleboxes present a flat bottom that is best suited for storage on shelving,while other file box designs such as the automatic bottom style boxeshave cutouts and rough edges along with creases in the bottom flap(s)that can catch on shelving, and thus typically are not well suited foruse in situations in which the boxes are going to be stored on shelves.

There are at least two problems with the file bottom box design that areaddressed by the present disclosure. For one, the design requires theuser to read and follow fairly complex assembly instructions, takingtime and labor to put the box together. This involves folding the bottompanels up in a specific sequence which forms the bottom structure. Thenthe top flaps need to be folded over and inward to form the double wallstructure on the length panels and triple wall structure on the widthpanels. This is a time consuming and complicated process for theconsumer.

A second problem is the size of the file bottom box: the box form (theintermediate form in which the blank has been partially folded and liesflat for shipping and storage, and is ready to be assembled into afunctional box) is relatively large. The box in its flat form has allthe folding flaps top and bottom sticking out, waiting for assembly.This makes the box in the knocked down flat position, a large footprintto handle when delivering to customers through passage ways, doorways,and in an office environment. Also, more area needs to be devoted toshipping and storage of these box forms. The disclosure reduces thisfootprint when in the flat (i.e., the box form before it is squared up)by 33%, a huge material handling and shipping savings, and an enormousincrease in convenience.

SUMMARY

This disclosure features a box for file storage and the like. The box ismade from a unitary blank of material. The box, when assembled, has fourinterconnected sidewalls that define an open storage area between them.The sidewalls are typically each rectangular in shape, to define agenerally rectangular prism-shaped storage area.

In an example the pre-folded file bottom box form is made from a unitaryblank of material comprising a blank of corrugated material that is diecut and creased so as to form a series of panels and flaps arranged inthree rows of four panels or flaps each that define four columns, afirst row comprising four panels that end up in the box as reinforcingsidewall and end wall panels, a middle row contiguous with the first rowand comprising four panels that end up in the box as the box sidewalland end wall panels, and a third row coupled to the second row andcomprising first and second panels and two flaps, the first and secondpanels making up the bottom of the box and the two flaps contiguous withthe first third-row panel and making up portions of the two end-walls.The four panels of the first row are folded onto the four panels of thesecond row. The blank is then folded along two of the fold lines locatedbetween columns, and the edges of the end panels of the middle row areglued together, to create the completed form. The disclosure includes abox created from this pre-folded file bottom box form.

The four panels of the first row may be separated from one another byslots. The slots may be skip slots that comprise a small region ofmaterial that spans the slots such that two panels separated by a slotare connected by the small region. The four panels of the first row maylie against but are not fixed to the four panels of the second row. Thefour panels of the first row may be glued to the four panels of thesecond row. The edges of the end panels of the middle row may befastened together by gluing, stitching or stapling.

The disclosure also features a method of creating a pre-folded filebottom box form made from a unitary blank of material comprisingproviding a blank of corrugated material that is die cut and creased soas to form a series of panels and flaps arranged in three rows of fourpanels or flaps each that define four columns, a first row comprisingfour panels that end up in the box as sidewall and end wall panels, amiddle row contiguous with the first row and comprising four panels thatend up in the box as box sidewall and end wall panels, and a third rowcoupled to the second row and comprising first and second panels and twoflaps, the first and second panels making up the bottom of the box andthe two flaps contiguous with the first third-row panel and making upportions of the two end-walls. The four panels of the first row arefolded onto the four panels of the second row. Then the blank is foldedalong two of the fold lines located between columns. Then the edges ofthe end panels of the middle row are glued together, to create thecompleted form.

The four panels of the first row may be separated from one another byslots. The slots may be skip slots that comprise a small region ofmaterial that spans the slots such that two panels separated by a slotare connected by the small region. The four panels of the first row maylie against but are not fixed to the four panels of the second row. Thefour panels of the first row may be glued to the four panels of thesecond row. The edges of the end panels of the middle row may befastened together by gluing, stitching or stapling.

An open-top box may be created from the box form by squaring up the boxform into an open rectangular box shape, pulling a first panel of thethird row up inside the box shape, folding the two flaps of the thirdrow onto the second panel of the third row, pushing the second panel ofthe third row down such that it lies generally at right angles to thefour sidewalls, unfolding the two flaps of the third row against the twomiddle row panels that make up the end walls, and pushing the firstpanel of the third row down onto the second panels of the third row.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a top inside view of a blank used to create an example of thebox form, before folding.

FIG. 2 shows the top row folded down and glued to the middle row.

FIG. 3 shows the form in the state shown in FIG. 2, and then partiallyfolded along vertical fold lines between columns.

FIG. 4 shows the fully assembled box form ready for shipment, storageand then folding into a box.

DETAILED DESCRIPTION OF EXAMPLES

An example of a box form is created from the unitary blank of material10 shown in FIG. 1. Blank 10 may be constructed of any material thatwill form a stiff panel surface. Preferably, blank 10 is made from asingle thickness corrugated material (corrugated paper or corrugatedplastic), that is a material with two layers of linerboard separated bya single layer of fluted material. Such a corrugated material can beconstructed from different substances, as is known in the art. Thematerial can have several different constructions. Corrugated materialis typically constructed from fiber materials or plastic materials.

Blank 10 is formed through die cutting and creasing of corrugatedmaterial as is known in the art. In one non-limiting example, blank 10is about 75⅛ inches wide and about 32 7/16 inches high. FIG. 1 shows theblank from the side that will form the inside of the box. Lines 42-44and 71-73 illustrate fold lines or creases where the form is adapted tobe folded. In the example, blank 10 is pre-folded and glued such thatthe panels that make up the sidewall and end wall reinforcements areoverlaid over and glued to the panels that make up two sidewalls and thetwo end walls. As a result, the form has an area that is only abouttwo-thirds that of the typical form. This results in space savings intrucks, shipping containers and other means by which box forms areshipped, as well as warehouses, storage rooms and other locations whereforms are stored by distributors or end-users before the forms arefolded into boxes.

By pre-folding the top four panels (which become sidewallreinforcements) into position during the manufacturing process, thefootprint of the box in the knocked down flat position is reduced by33%. This is an important improvement because it allows for greaterfreight efficiencies, easier delivery through narrow doorways, hallwaysand within the office environment. From an ergonomic point of view,having a box foot print that is 33% smaller makes it easier for peopleto handle the box prior to assembly and reduces the risk of potentialinjury, especially when bundles of ten or more are being handled.Bundled units of ten or more are how these products are typicallydelivered. Having a third less width in the footprint allows peoplecarrying the box forms to more easily handle them.

Blank 10 essentially defines three rows of panels and flaps labeled A, Band C, and four columns of panels and flaps labeled D, E, F and G.Panels 16 and 18 will eventually form the bottom of the box with panel16 on the outside. Since panel 16 does not have any folds or creases init, the resulting box will sit flat on shelves or other storagelocations and is easier to handle than other boxes such as the automaticbottom style boxes in which the bottom panel has folds or creases in itand so does not present a flat outer surface.

The pre-folded file bottom box form 80 can be created as follows.Beginning with form 10, panels 34, 38, 32 and 36 are folded alonghorizontal crease 71 onto panels 24, 40, 28 and 20, respectively.Adhesive is applied before folding. This secures the panels of thedouble thickness sidewalls and end walls together, rather than relyingon friction; this makes the construction more secure. As a result, thefour panels of row A are now located on top of the four panels in row B,as shown in FIG. 2. The form is then folded along vertical fold lines 42and 44 (as shown in FIG. 3), and extension 24 of panel 30 is glued tolocation 26 of panel 20; extension 24 is defined by score line 25 so itcan fold relative to panel 30, thus allowing box form 80 to lie flat.This creates the pre-folded file bottom box form 80 shown in FIG. 4.This flat box form only occupies an area equal to that of rows B and Cand columns D and G.

This box form is then folded into a functional box as follows: Thepre-folded file bottom box is squared up to form a rectangular shape.Panel 18 is pulled up inside the box against panel 20 to make room forthe folding of panels 12, 16 and 14. Panel 16 is then pushed down suchthat it lies at right angles to the four sidewalls; flaps 14 and 12 arefirst folded flat against panel 16 to allow all three panels to foldinside the box. Once inside the squared up box, panel 16 forms thebottom outside of the box at a right angle to panel 40. Panel 12 thenunfolds against panel 30 and panel 14 unfolds against panel 28. Panel 18is pushed down onto panel 16. This forms a double thickness flat bottomto the box.

In an alternative example the panels that make up the sidewall and endwall reinforcements are not fastened (e.g., by gluing, stitching orstapling) to the panels that make up two sidewalls and the two endwalls. Instead, they are held by friction. To accomplish this slots 101,102 and 103 would be fashioned as “skip slots” (as known in the trade)wherein a small region of material would span the slots and directlyinterconnect the two adjacent panels, thus securing panels 34, 38, 32and 36 as one unit. This allows the four panels in row A to be foldedover all at once along fold line 71 against panels 30, 40, 28 and 20making up row B. The tolerances (sizes) of the panels in row A would beadjusted so they would fit snugly and accomplish a friction fit when thebox is folded over and sealed with the side seam 24 mating with area 26.The bottom of the box would be assembled as previously described.

1. A pre-folded file bottom box form, comprising: a unitary blank ofcorrugated material that is die cut and creased so as to form a seriesof panels and flaps arranged in three rows of four panels or flaps eachthat define four columns, the blank comprising: a first row comprisingfour panels that end up in the box as reinforcing sidewall and end wallpanels; a middle row contiguous with the first row and comprising fourpanels that end up in the box as sidewall and end wall panels; and athird row coupled to the second row and comprising first and secondpanels and two flaps, the first and second panels making up the bottomof the box and the two flaps contiguous with the first third-row paneland making up portions of the two end-walls; wherein the four panels ofthe first row are folded onto the four panels of the second row; andwherein the blank is then folded along two of the fold lines locatedbetween columns, and the edges of the end panels of the middle row arefastened together, to create the completed form.
 2. The box form ofclaim 1 wherein the four panels of the first row are separated from oneanother by slots.
 3. The box form of claim 2 wherein the four panels ofthe first row are glued to the four panels of the second row.
 4. The boxform of claim 2 wherein the slots are skip slots that comprise a smallregion of material that spans the slots such that two panels separatedby a slot are connected by the small region.
 5. The box form of claim 4wherein the four panels of the first row lie against but are not fixedto the four panels of the second row.
 6. The box form of claim 1 whereinthe edges of the end panels of the middle row are fastened together bygluing, stitching or stapling.
 7. A box created from the box form ofclaim
 1. 8. A method of creating a pre-folded file bottom box form madefrom a unitary blank of material, comprising: i) providing a blank ofcorrugated material that is die cut and creased so as to form a seriesof panels and flaps arranged in three rows of four panels or flaps eachthat define four columns, a first row comprising four panels that end upin the box as reinforcing sidewall and end wall panels, a middle rowcontiguous with the first row and comprising four panels that end up inthe box as sidewall and end wall panel, and a third row coupled to thesecond row and comprising first and second panels and two flaps, thefirst and second panels making up the bottom of the box and the twoflaps contiguous with the first third-row panel and making up portionsof the two end-walls; ii) folding the four panels of the first row tothe four panels of the second row; iii) then folding the blank along twoof the fold lines located between columns; and iv) then fasteningtogether the edges of the end panels of the middle row, to create thecompleted form.
 9. The method of claim 8 wherein the four panels of thefirst row are separated from one another by slots.
 10. The method ofclaim 9 wherein the four panels of the first row are glued to the fourpanels of the second row.
 11. The method of claim 9 wherein the slotsare skip slots that comprise a small region of material that spans theslots such that two panels separated by a slot are connected by thesmall region.
 12. The method of claim 11 wherein the four panels of thefirst row lie against but are not fixed to the four panels of the secondrow.
 13. The method of claim 8 wherein the edges of the end panels ofthe middle row are fastened together by gluing, stitching or stapling.14. The method of claim 8 further comprising: v) creating from the boxform an open-top box.
 15. The method of claim 14 wherein creating fromthe box form an open-top box comprises the following steps: vi) squaringup the box form into an open rectangular box shape; vii) pulling a firstpanel of the third row up inside the box shape; viii) folding the twoflaps of the third row onto the second panel of the third row andpulling the panel up inside the box shape; ix) pushing the second panelof the third row down such that it lies generally at right angles to thefour sidewalls; x) unfolding the two flaps of the third row against thetwo middle row panels that make up the end walls; and xi) pushing thefirst panel of the third row down onto the second panel of the thirdrow.